724KLoaderRepair

TECHNICAL MANUAL724K Loader Repair

TM10697 12MAY09 (ENGLISH)

For complete service information also see:

724K Loader Test Manual . . . . . . . . . . . . . . TM10696724K Loader Operator’s Manual . . . . . . . . . OMT2317339.0 L OEM Diesel Engines—Base EngineRepair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CTM4009.0 L Diesel Engines—Level 14 ElectronicFuel System with Denso HPCR . . . . . . . . . . CTM385TeamMate IV 1200 and 1400 SeriesInboard Planetary Axles . . . . . . . . . . . . . . . . CTM442120 Series Hydraulic Cylinders . . . . . . . . . . TM-H120A125 Series Hydraulic Cylinders . . . . . . . . . . TM-H125A185 Series Hydraulic Cylinders . . . . . . . . . . TM-H185ASuper Caddy Oil Cleanup Procedure . . . . . . CTM310JDLink / ZXLink Machine MonitoringSystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CTM10006Specifications Manual . . . . . . . . . . . . . . . . . . SP458

Worldwide ConstructionAnd Forestry Division

LITHO in U.S.A.

Introduction

DX,TMIFC –19–29SEP98–1/1

Foreword

This manual is written for an experienced technician.Essential tools required in performing certain servicework are identified in this manual and arerecommended for use.

Live with safety: Read the safety messages in theintroduction of this manual and the cautions presentedthroughout the text of the manual.

This is the safety-alert symbol. When you see thissymbol on the machine or in this manual, be alert tothe potential for personal injury.

Technical manuals are divided in two parts: repair andoperation and tests. Repair sections tell how to repairthe components. Operation and tests sections help youidentify the majority of routine failures quickly.

Information is organized in groups for the variouscomponents requiring service instruction. At thebeginning of each group are summary listings of allapplicable essential tools, service equipment and tools,other materials needed to do the job, service parts kits,specifications, wear tolerances, and torque values.

Technical Manuals are concise guides for specificmachines. They are on-the-job guides containing onlythe vital information needed for diagnosis, analysis,testing, and repair.

Fundamental service information is available fromother sources covering basic theory of operation,fundamentals of troubleshooting, general maintenance,and basic type of failures and their causes.

TM10697 (12MAY09) 724K Loader051209

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Contents00

SECTION 17—Frame or Supporting StructureSECTION 00—General InformationGroup 1740—Frame InstallationGroup 0001—Safety InformationGroup 1746—Frame Bottom GuardsGroup 1749—Chassis WeightsSECTION 01—Wheels

Group 0110—Powered Wheels and Fasteners 01SECTION 18—Operator’s StationGroup 1800—Removal and Installation

SECTION 02—Axles and Suspension Systems Group 1810—Operator EnclosureGroup 0200—Removal and Installation Group 1821—Seat and Seat BeltGroup 0225—Axle Shafts and U-Joints Group 1830—Heating and Air ConditioningGroup 0250—Axle Shaft, Bearings, Reduction

Gears SECTION 19—Sheet Metal and StylingGroup 0260—Hydraulic System Group 1910—Hood or Engine Enclosure

SECTION 31—LoaderSECTION 03—TransmissionGroup 3102—BucketGroup 0300—Removal and Installation

02

Group 3140—FramesGroup 0350—Gears, Shafts, Bearings and PowerGroup 3160—Hydraulic SystemShift Clutch

Group 0360—Hydraulic SystemSECTION 99—Dealer Fabricated Tools

Group 9900—Dealer Fabricated ToolsSECTION 04—Engine

Group 0400—Removal and Installation

SECTION 05—Engine Auxiliary SystemsGroup 0505—Cold Weather Starting AidsGroup 0510—Cooling System

03

Group 0520—Intake SystemGroup 0530—External Exhaust SystemGroup 0560—External Fuel Supply Systems

SECTION 07—Dampener DriveGroup 0752—Elements

SECTION 09—Steering SystemGroup 0960—Hydraulic System

04

SECTION 10—Service BrakesGroup 1011—Active ElementsGroup 1060—Hydraulic System

SECTION 11—Park BrakeGroup 1111—Active ElementsGroup 1160—Hydraulic System

All information, illustrations and specifications in this manual are based onthe latest information available at the time of publication. The right isreserved to make changes at any time without notice.

05

COPYRIGHT 2009DEERE & COMPANY

Moline, IllinoisAll rights reserved

A John Deere ILLUSTRUCTION ManualPrevious EditionsCopyright 2008

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Section 00General Information

Contents

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Group 0001—Safety InformationRecognize Safety Information . . . . . . . . . . . .00-0001-1Follow Safety Instructions . . . . . . . . . . . . . . .00-0001-1Operate Only If Qualified. . . . . . . . . . . . . . . .00-0001-2Wear Protective Equipment. . . . . . . . . . . . . .00-0001-2Avoid Unauthorized Machine

Modifications . . . . . . . . . . . . . . . . . . . . . . .00-0001-2Add Cab Guarding For Special Uses . . . . . .00-0001-3Inspect Machine . . . . . . . . . . . . . . . . . . . . . .00-0001-3Stay Clear of Moving Parts . . . . . . . . . . . . . .00-0001-3Avoid High-Pressure Fluids . . . . . . . . . . . . . .00-0001-4Avoid High-Pressure Oils . . . . . . . . . . . . . . .00-0001-4Beware of Exhaust Fumes . . . . . . . . . . . . . .00-0001-5Prevent Fires. . . . . . . . . . . . . . . . . . . . . . . . .00-0001-5Clean Trash from Machine . . . . . . . . . . . . . .00-0001-6Prevent Battery Explosions . . . . . . . . . . . . . .00-0001-6Handle Chemical Products Safely . . . . . . . . .00-0001-6Dispose of Waste Properly . . . . . . . . . . . . . .00-0001-7Prepare for Emergencies. . . . . . . . . . . . . . . .00-0001-7Use Steps and Handholds Correctly . . . . . . .00-0001-7Start Only From Operator’s Seat . . . . . . . . . .00-0001-8Use and Maintain Seat Belt. . . . . . . . . . . . . .00-0001-8Prevent Unintended Machine Movement . . . .00-0001-9Avoid Work Site Hazards . . . . . . . . . . . . . .00-0001-10Use Special Care When Operating

Loader . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0001-11Keep Riders Off Machine . . . . . . . . . . . . . .00-0001-11Avoid Backover Accidents . . . . . . . . . . . . . .00-0001-12Avoid Machine Tip Over . . . . . . . . . . . . . . .00-0001-13Operating on Slopes . . . . . . . . . . . . . . . . . .00-0001-13Operating or Traveling On Public Roads . . .00-0001-14Inspect and Maintain ROPS . . . . . . . . . . . .00-0001-14Add and Operate Attachments Safely . . . . .00-0001-14Park And Prepare For Service Safely . . . . .00-0001-15Service Cooling System Safely . . . . . . . . . .00-0001-15Service Tires Safely . . . . . . . . . . . . . . . . . .00-0001-16Remove Paint Before Welding or

Heating . . . . . . . . . . . . . . . . . . . . . . . . . .00-0001-17Make Welding Repairs Safely . . . . . . . . . . .00-0001-18Drive Metal Pins Safely . . . . . . . . . . . . . . . .00-0001-18

TM10697 (12MAY09) 00-1 724K Loader051209

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TM10697 (12MAY09) 00-2 724K Loader051209

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Group 0001Safety Information

0000011

TX03679,00016CC –19–03NOV08–1/1

Recognize Safety Information

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This is the safety alert symbol. When you see thissymbol on your machine or in this manual, be alertfor the potential of personal injury.

Follow the precautions and safe operating practiceshighlighted by this symbol.

A signal word — DANGER, WARNING, or CAUTION — isused with the safety alert symbol. DANGER identifies themost serious hazards.

On your machine, DANGER signs are red in color,WARNING signs are orange, and CAUTION signs areyellow. DANGER and WARNING signs are located nearspecific hazards. General precautions are on CAUTIONlabels.

TX03679,00016F9 –19–18OCT07–1/1

Follow Safety Instructions

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Read the safety messages in this manual and on themachine. Follow these warnings and instructions carefully.Review them frequently. Keep safety signs in goodcondition. Replace missing or damaged safety signs.Replacement safety signs are available from yourauthorized John Deere dealer.

Be sure all operators of this machine understand everysafety message. Replace operator’s manual and safetylabels immediately if missing or damaged.

TM10697 (12MAY09) 00-0001-1 724K Loader051209

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Safety Information

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TX03679,00016FA –19–03NOV08–1/1

Operate Only If Qualified

Do not operate this machine unless you have read theoperator’s manual carefully and you have beenqualified by supervised training and instruction.

Familiarize yourself with the job site and yoursurroundings before operating. Try all controls and

machine functions with the machine in an open areabefore starting to work.

Know and observe all safety rules that may apply toyour work situation and your work site.

TX03679,00016D0 –19–03NOV08–1/1

Wear Protective Equipment

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Guard against injury from flying pieces of metal or debris;wear goggles or safety glasses.

Wear close fitting clothing and safety equipmentappropriate to the job.

Prolonged exposure to loud noise can cause impairmentor loss of hearing. Wear suitable hearing protection suchas earmuffs or earplugs to protect against objectionable oruncomfortable loud noises.

AM40430,00000A9 –19–14JAN08–1/1

Avoid Unauthorized Machine Modifications

John Deere recommends using only genuine JohnDeere replacement parts to ensure machineperformance. Never substitute genuine John Deereparts with alternate parts not intended for theapplication as these can create hazardous situations orhazardous performance. Non-John Deere Parts, or anydamage or failures resulting from their use are notcovered by any John Deere warranty.

Modifications of this machine, or addition ofunapproved products or attachments, may affect

machine stability or reliability, and may create a hazardfor the operator or others near the machine. Theinstaller of any modification which may affect theelectronic controls of this machine is responsible forestablishing that the modification does not adverselyaffect the machine or its performance.

Always contact an authorized John Deere dealerbefore making machine modifications that change theintended use, weight or balance of the machine, orthat alter machine controls, performance or reliability.

TM10697 (12MAY09) 00-0001-2 724K Loader051209

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Safety Information

0000013

TX03679,00017C6 –19–18OCT07–1/1

Add Cab Guarding For Special Uses

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Special work situations or machine attachments maycreate an environment with falling or flying objects.Loading logs, using fork attachments, or operating inwaste management applications requires special worktools. Added cab guarding to protect the operator mayalso be required.

Use load-clamping grapples to keep bulky loads fromfalling and add special screens or guarding when objectsmay be directed toward the cab. Contact your authorizedJohn Deere dealer for information on devices intended toprotect the operator from falling or flying objects in specialwork situations.

TX03679,0001734 –19–03NOV08–1/1

Inspect Machine

T66

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Inspect machine carefully each day by walking around itbefore starting.

Keep all guards and shields in good condition andproperly installed. Fix damage and replace worn or brokenparts immediately. Pay special attention to hydraulichoses and electrical wiring.

TX03679,00016D2 –19–03NOV08–1/1

Stay Clear of Moving Parts

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01Entanglements in moving parts can cause serious injury.

Stop engine before examining, adjusting or maintainingany part of machine with moving parts.

Keep guards and shields in place. Replace any guard orshield that has been removed for access as soon asservice or repair is complete.

TM10697 (12MAY09) 00-0001-3 724K Loader051209

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Safety Information

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DX,FLUID –19–03MAR93–1/1

Avoid High-Pressure Fluids

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Escaping fluid under pressure can penetrate the skincausing serious injury.

Avoid the hazard by relieving pressure beforedisconnecting hydraulic or other lines. Tighten allconnections before applying pressure.

Search for leaks with a piece of cardboard. Protect handsand body from high pressure fluids.

If an accident occurs, see a doctor immediately. Any fluidinjected into the skin must be surgically removed within afew hours or gangrene may result. Doctors unfamiliar withthis type of injury should reference a knowledgeablemedical source. Such information is available from Deere& Company Medical Department in Moline, Illinois, U.S.A.

TX03679,00016D3 –19–03NOV08–1/1

Avoid High-Pressure Oils

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This machine uses a high-pressure hydraulic system.Escaping oil under pressure can penetrate the skincausing serious injury.

Never search for leaks with your hands. Protect hands.Use a piece of cardboard to find location of escaping oil.Stop engine and relieve pressure before disconnectinglines or working on hydraulic system.

If hydraulic oil penetrates your skin, see a doctorimmediately. Injected oil must be removed surgicallywithin hours or gangrene may result. Contact aknowledgeable medical source or the Deere & CompanyMedical Department in Moline, Illinois, U.S.A.

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Safety Information

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TX03679,00016D4 –19–03NOV08–1/1

Beware of Exhaust Fumes

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Prevent asphyxiation. Engine exhaust fumes can causesickness or death.

If you must operate in an enclosed space, provideadequate ventilation. Use an exhaust pipe extension toremove the exhaust fumes or open doors and windows tobring outside air into the area.

TX03679,00016F5 –19–03NOV08–1/1

Prevent Fires

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Handle Fuel Safely: Store flammable fluids away fromfire hazards. Never refuel machine while smoking or whennear sparks or flame.

Clean Machine Regularly: Keep trash, debris, greaseand oil from accumulating in engine compartment, aroundfuel lines, hydraulic lines, exhaust components, andelectrical wiring. Never store oily rags or flammablematerials inside a machine compartment.

Maintain Hoses and Wiring: Replace hydraulic hosesimmediately if they begin to leak, and clean up any oilspills. Examine electrical wiring and connectors frequentlyfor damage.

Keep A Fire Extinguisher Available: Always keep amultipurpose fire extinguisher on or near the machine.Know how to use extinguisher properly.

TM10697 (12MAY09) 00-0001-5 724K Loader051209

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Safety Information

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OUT4001,00000E3 –19–27FEB09–1/1

Clean Trash from Machine

T66

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T88

Keep engine compartment, radiator, batteries, hydrauliclines, exhaust components, fuel tank, and operator’sstation clean and free of debris.

Clean any oil spills or fuel spills on machine surfaces.

Temperature in engine compartment may go upimmediately after engine is stopped. BE ON GUARD FORFIRES DURING THIS PERIOD.

Open access door(s) to cool the engine faster, and cleanengine compartment.

TX03679,000174A –19–03NOV08–1/1

Prevent Battery Explosions

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Battery gas can explode. Keep sparks, lighted matches,and open flame away from the top of battery.

Never check battery charge by placing a metal objectacross the posts. Use a voltmeter or hydrometer.

Do not charge a frozen battery; it may explode. Warmbattery to 16°C (60°F).

TX03679,00016D7 –19–03JAN07–1/1

Handle Chemical Products Safely

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00Exposure to hazardous chemicals can cause seriousinjury. Under certain conditions, lubricants, coolants,paints and adhesives used with this machine may behazardous.

If uncertain about safe handling or use of these chemicalproducts, contact your authorized dealer for a MaterialSafety Data Sheet (MSDS) or go to internet websitehttp://www.jdmsds.com. The MSDS describes physicaland health hazards, safe use procedures, and emergencyresponse techniques for chemical substances. FollowMSDS recommendations to handle chemical productssafely.

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Safety Information

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TX03679,0001733 –19–03NOV08–1/1

Dispose of Waste Properly

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Improper disposal of waste can threaten the environment.Fuel, oils, coolants, filters and batteries used with thismachine may be harmful if not disposed of properly.

Never pour waste onto the ground, down a drain, or intoany water source.

Air conditioning refrigerants can damage the atmosphere.Government regulations may require using a certifiedservice center to recover and recycle used refrigerants.

If uncertain about the safe disposal of waste, contact yourlocal environmental or recycling center or your dealer formore information.

TX03679,000174B –19–03NOV08–1/1

Prepare for Emergencies

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Be prepared if an emergency occurs or a fire starts.

Keep a first aid kit and fire extinguisher handy.

Keep emergency numbers for doctors, ambulance service,hospital, and fire department near your telephone.

TX03679,00016F2 –19–15MAR07–1/1

Use Steps and Handholds Correctly

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Prevent falls by facing the machine when getting on andoff. Maintain 3-point contact with steps and handrails.Never use machine controls as handholds.

Use extra care when mud, snow, or moisture presentslippery conditions. Keep steps clean and free of greaseor oil. Never jump when exiting machine. Never mount ordismount a moving machine.

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Safety Information

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TX03679,0001799 –19–03JAN07–1/1

Start Only From Operator’s Seat

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00Avoid unexpected machine movement. Start engine onlywhile sitting in operator’s seat. Ensure all controls andworking tools are in proper position for a parked machine.

Never attempt to start engine from the ground. Do notattempt to start engine by shorting across the startersolenoid terminals.

TX03679,00016DD –19–03NOV08–1/1

Use and Maintain Seat Belt

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00Use seat belt when operating machine. Remember tofasten seat belt when loading and unloading from trucksand during other uses.

Examine seat belt frequently. Be sure webbing is not cutor torn. Replace seat belt immediately if any part isdamaged or does not function properly.

The complete seat belt assembly should be replacedevery 3 years, regardless of appearance.

TM10697 (12MAY09) 00-0001-8 724K Loader051209

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Safety Information

0000019

DP99999,00000A3 –19–02MAY08–1/1

Prevent Unintended Machine Movement

TX

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1—Park Brake Switch2—Pilot Enable/Boom Down Switch

Lower all equipment to the ground during workinterruptions. Place transmission control in neutral, presspark brake switch (1) to engage park brake, press pilotenable/boom down switch (2) to disable the hydraulics,and stop engine before allowing anyone to approach themachine.

Follow these same precautions before standing up,leaving the operator’s seat, or exiting the machine.

TM10697 (12MAY09) 00-0001-9 724K Loader051209

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Safety Information

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DP99999,0000113 –19–23JUN08–1/1

Avoid Work Site Hazards

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Avoid contact with gas lines, buried cables and waterlines. Call utility line location services to identify allunderground utilities before starting work.

Prepare work site properly. Avoid operating nearstructures or objects that could fall onto the machine.Clear away debris that could move unexpectedly if runover.

Avoid boom or attachment contact with overheadobstacles or overhead electrical lines. Never movemachine closer than 3 m (10 ft) plus twice the lineinsulator length to overhead wires.

Keep bystanders clear at all times. Keep bystandersaway from raised booms, attachments, and unsupportedloads. Avoid swinging or raising booms, attachments, orloads over or near personnel. Use barricades or a signalperson to keep vehicles and pedestrians away. Use asignal person if moving machine in congested areas orwhere visibility is restricted. Always keep signal person inview. Coordinate hand signals before starting machine.

Operate only on solid footing with strength sufficient tosupport machine. Be especially alert working nearembankments or excavations.

Avoid working under over-hanging embankments orstockpiles that could collapse under or on machine.

Reduce machine speed when operating with tool on ornear ground when obstacles may be hidden (e.g., duringsnow removal or clearing mud, dirt, etc.). At high speedshitting obstacles (rocks, uneven concrete or manholes)can cause a sudden stop. Always wear your seatbelt.

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Safety Information

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TX03768,0000B70 –19–14MAY01–1/1

Use Special Care When Operating Loader

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Never use the loader to lift people. Do not allowanyone to ride in the bucket or use the bucket as awork platform.

Operate carefully with raised loads. Raising the loadreduces machine stability, especially on side slopes or anunstable surface. Drive and turn slowly with a raised load.

Ensure that objects in the bucket are secure. Do notattempt to lift or carry objects that are too big or too longto fit inside the bucket unless secured with an adequatechain or other device. Keep bystanders away from raisedloads.

Be careful when lifting objects. Never attempt to liftobjects too heavy for your machine. Assure machinestability and hydraulic capability with a test lift beforeattempting other maneuvers. Use an adequate chain orsling and proper rigging techniques to attach and stabilizeloads. Never lift an object above or near another person.

TX03679,000179B –19–20APR01–1/1

Keep Riders Off Machine

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Only allow operator on machine.

Riders are subject to injury. They may fall from machine,be caught between machine parts, or be struck by foreignobjects.

Riders may obstruct operator’s view or impair his ability tooperate machine safely.

TM10697 (12MAY09) 00-0001-11 724K Loader051209

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Safety Information

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DP99999,00001D7 –19–26AUG08–1/1

Avoid Backover Accidents

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Before moving machine, be sure that all persons areclear of machine path. Turn around and look directly forbest visibility. Use mirrors to assist in checking all aroundmachine. Keep windows and mirrors clean, adjusted, andin good repair.

Be certain reverse warning alarm is working properly.

Use a signal person when backing if view isobstructed or when in close quarters. Keep signalperson in view at all times. Use prearranged hand signalsto communicate.

Do not rely on the rear camera and rear object detectionsystems to determine if personnel are behind themachine. The system has limitations due to maintenancepractices, environmental conditions, and operating range.

TM10697 (12MAY09) 00-0001-12 724K Loader051209

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Safety Information

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TX03679,000179D –19–02MAY01–1/1

Avoid Machine Tip Over

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Use seat belt at all times.

Do not jump if the machine tips. You will be unlikely tojump clear and the machine may crush you.

Load and unload from trucks or trailers carefully. Besure truck is wide enough and on a firm level surface. Useloading ramps and attach them properly to truck bed.

Be careful on slopes. Avoid sharp turns. Balance loadsso weight is evenly distributed and load is stable. Carrytools and loads close to the ground to aid visibility andlower center of gravity. Use extra care on soft, rocky orfrozen ground.

Know the capacity of the machine. Do not overload. Becareful with heavy loads. Using oversize buckets or liftingheavy objects reduces machine stability.

Ensure solid footing. Use extra care in soft groundconditions that may not uniformly support the wheels,especially when raising the boom. Do not operate close tobanks or open excavations that may cave in and causemachine to tip or fall.

TX03679,000179E –19–14MAY01–1/1

Operating on Slopes

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Avoid side slope travel whenever possible. Drive up steepslope in forward and down in reverse.

Select low gear speed before starting down slope. Thegrade of the slope will be limited by ground condition andload being handled.

Use service brakes to control speed. Sudden brakeapplication with a loaded bucket on downhill side couldcause machine to tip forward.

TM10697 (12MAY09) 00-0001-13 724K Loader051209

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Safety Information

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TX03679,00017C8 –19–02MAR07–1/1

Operating or Traveling On Public Roads

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Machines that work near vehicle traffic or travel slowerthan normal highway speeds must have proper lightingand markings to assure they are visible to other drivers.

Install additional lights, beacons, slow moving vehicle(SMV) emblems, or other devices and use as required tomake the machine visible and identify it as a workmachine. Check state and local regulations to assurecompliance. Keep these devices clean and in workingcondition.

TX03679,000179F –19–07SEP06–1/1

Inspect and Maintain ROPS

A damaged roll-over protective structure (ROPS)should be replaced, not reused.

The protection offered by ROPS will be impaired ifROPS is subjected to structural damage, is involved inan overturn incident, or is in any way altered bywelding, bending, drilling, or cutting.

If ROPS was loosened or removed for any reason,inspect it carefully before operating the machine again.

To maintain the ROPS:

• Replace missing hardware using correct gradehardware.

• Check hardware torque.• Check isolation mounts for damage, looseness or

wear; replace them if necessary.• Check ROPS for cracks or physical damage.

TX03679,00016F0 –19–24JAN07–1/1

Add and Operate Attachments Safely

Always verify compatibility of attachments bycontacting your authorized dealer. Adding unapprovedattachments may affect machine stability or reliability,and may create a hazard for others near the machine.

Ensure that a qualified person is involved inattachment installation. Add guards to machine ifoperator protection is required or recommended. Verify

that all connections are secure and attachmentresponds properly to controls.

Carefully read attachment manual and follow allinstructions and warnings. In an area free ofbystanders and obstructions, carefully operateattachment to learn its characteristics and range ofmotion.

TM10697 (12MAY09) 00-0001-14 724K Loader051209

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